Removal And Installation

TIMING CHAIN


Removal and Installation


REMOVAL
1. Remove the following parts.
- PCV hose: Exploded View.
- Intake manifold: Exploded View.
- Ignition coil: Exploded View.
- Drive belt: Removal And Installation.
- Drive belt auto-tensioner: Exploded View.
2. Remove engine mounting bracket.
3. Remove rocker cover. Exploded View.
4. Remove oil pan (lower). Exploded View.
5. Remove oil pan (upper), and oil strainer. Exploded View.
6. Remove intake valve timing control cover.





- Loosen bolts in the reverse order as shown in the figure.
- Use a seal cutter [SST: KV10111100 (J-37228)] or equivalent tool to cut liquid gasket for removal.

CAUTION:
Be careful not to damage mounting surface.
7. Pull chain guide between camshaft sprockets out through front cover.
8. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:





a. Rotate crankshaft pulley clockwise and align TDC mark to timing indicator on front cover.





b. At the same time, line up the mating marks on camshaft sprockets, and paint indelible mating marks on timing chain link plate.
- If not, rotate crankshaft pulley one more turn to align mating marks to the positions in the figure.
9. Remove crankshaft pulley with the following procedure:





a. Fix crankshaft pulley with a pulley holder (commercial service tool), loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position.





b. Attach a pulley puller (commercial service tool) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley.
10. Remove front cover with the following procedure:





a. Loosen mounting bolts in the reverse order as shown in the figure, and remove them.





b. Use a seal cutter [SST: KV10111100 (J-37228)] or equivalent tool to cut liquid gasket for removal.

CAUTION:
Be careful not to damage mounting surface.
11. If front oil seal needs to be replaced, lift it with a suitable tool, and remove it.

CAUTION:
Be careful not to damage front cover.
12. Remove timing chain and camshaft sprockets with the following procedure:





a. Push in chain tensioner plunger. Insert a stopper pin into hole on chain tensioner body to secure chain tensioner plunger and remove chain tensioner.

NOTE:
Use approximately 0.5 mm (0.020 in) dia. hard metal pin as a stopper pin.





b. Secure hexagonal part of camshaft with a wrench. Loosen camshaft sprocket mounting bolts and remove timing chain and camshaft sprockets.

CAUTION:
Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.
13. Remove timing chain slack guide, timing chain tension guide and oil pump drive spacer.
14. Remove balancer unit timing chain tensioner with the following procedure:





a. Press stopper tab (A) in the direction shown in the figure to push the timing chain slack guide (B) toward balancer unit timing chain tensioner (1).
- The slack guide is released by pressing the stopper tab. As the result, the slack guide can be moved.
b. Insert a stopper pin (D) into tensioner body hole (C) to secure the timing chain slack guide.

NOTE:
Use a hard metal pin with the diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
c. Remove balancer unit timing chain tensioner.
- When the holes on lever and tensioner body cannot be aligned, align these holes by slightly moving the slack guide.
15. Remove balancer unit timing chain and crankshaft sprocket.





16. Loosen mounting bolts in the reverse order as shown in the figure, and remove balancer unit.

Arrow Indicates : Engine front

CAUTION:
Never disassemble balancer unit.

NOTE:
Use TORX socket (size E14).

INSTALLATION

NOTE:





The figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.
1. Check that crankshaft key points straight up.





2. Tighten mounting bolts in numerical order as shown in the figure with the following procedure, and install balancer unit.

Arrow Indicates : Engine front

CAUTION:
If mounting bolts are reused, check their outer diameter before installation. Procedures.
a. Apply new engine oil to threads and seat surfaces of mounting bolts.
b. Tighten No. 1 to 5 bolts.

Torque : 42.0 N.m (4.3 kg-m, 31 ft-lb)

c. Tighten No. 6 bolt.

Torque : 36.0 N.m (3.7 kg-m, 27 ft-lb)

d. Turn No. 1 to 5 bolts 120 degrees clockwise (angle tightening).

CAUTION:





Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
e. Turn No. 6 bolt 90 degrees clockwise (angle tightening).
f. Completely loosen all bolts.

Torque : 0 N.m (0 kg-m, 0 ft-lb)

CAUTION:
In this step, loosen bolts in the reverse order as shown in the figure.
g. Repeat step b to e.
3. Install crankshaft sprocket and balancer unit timing chain.





- Check that crankshaft sprocket is positioned with mating marks on cylinder block and crankshaft sprocket meeting at the top.
- Install it by aligning mating marks on each sprocket and balancer unit timing chain.
4. Install balancer unit timing chain tensioner.
- Be careful not to let mating marks of each sprocket and timing chain slip.
- After installation, check the mating marks have not slipped, then remove stopper pin and release tensioner sleeve.





5. Install timing chain and related parts.
- Install by aligning mating marks on each sprocket and timing chain.
- Before and after installing chain tensioner, check again to check that mating marks have not slipped.
- After installing chain tensioner, remove stopper pin, and check that tensioner moves freely.

CAUTION:
- For the following note, after the mating marks are aligned, keep them aligned by holding them with a hand.
- To avoid skipped teeth, never rotate crankshaft and camshaft until front cover is installed.

NOTE:
Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment.
6. Install front oil seal to front cover. Service and Repair.
7. Install front cover with the following procedure:
a. Install O-rings to cylinder head and cylinder block.





b. Apply a continuous bead of liquid gasket with a tube presser
(commercial service tool) to front cover as shown in the figure.





Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.

CAUTION:
- For bolt holes with marks (5 locations), apply liquid gasket out side the holes.
- Attaching should be done within 5 minutes after coating.

NOTE:
Application instruction differs depending on the position.
c. Check that mating marks of timing chain and each sprocket are still aligned. Then install front cover.

CAUTION:
Be careful not to damage front oil seal by interference with front end of crankshaft.





d. Tighten mounting bolts in numerical order as shown in the figure.
e. After all bolts are tightened, retighten them to specified torque in numerical order as shown in the figure.






CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to surface for fitting oil pan.





8. Install chain guide between camshaft sprockets.
9. Install intake valve timing control cover with the following procedure:
a. Install intake valve timing control solenoid valves to intake valve timing control cover if removed.
b. Install new oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control cover.
c. Install new O-ring to front cover.





d. Apply a continuous bead of liquid gasket with a tube presser
(commercial service tool) to intake valve timing control cover as shown in the figure.

a : dia 3.4 - 4.4 mm (0.134 - 0.173 in)

Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.

CAUTION:
Attaching should be done within 5 minutes after liquid gasket application.





e. Tighten mounting bolts in numerical order as shown in the figure.
10. Insert crankshaft pulley by aligning with crankshaft key.
- When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).

CAUTION:
Install protecting front oil seal lip section from any damage.
11. Tighten crankshaft pulley bolt.
- Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley bolt.
- Perform angle tightening with the following procedure:
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.

Torque : 42.1 N.m (4.3 kg-m, 31 ft-lb)






c. Put a paint mark on crankshaft pulley, mating with any one of six easy to recognize angle marks on bolt flange.
d. Turn another 60 degrees clockwise (angle tightening).
- Check the tightening angle with movement of one angle mark.
12. Install the following parts:
- Oil pan (upper) and oil strainer: Exploded View.
- Oil pan (lower): Exploded View.
- Rocker cover: Exploded View.
13. Install the engine mounting bracket to the engine as follow:





a. Tighten the bolts No. 3, 5 as shown in the figure. (temporarily)

Arrow Indicates : Engine front

b. Tighten the bolts in numerical order as shown in the figure. (specified torque)
14. Install all removed parts in the reverse order of removal.